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Someone used to offer aluminum wound brake housing a long time ago. Never heard of rupturing, don't think it's a problem with coiled housing, only linear strand shift housing. People did complain it was too squishy, though.If the outer diameter was not a limitation, I think all brake housing would be made of linear strands covered with something tough. this is what Yokozuna does, Jagwire offers some covers theirs with a braided Kevlar or other stuff. But all these suffer from extra friction, the liner is too close to the cable diameter. and they're a bit bigger than the standard 5mm, making some fitments awkward at best.

Someone used to offer aluminum wound brake housing a long time ago. Never heard of rupturing, don't think it's a problem with coiled housing, only linear strand shift housing. People did complain it was too squishy, though.If the outer diameter was not a limitation, I think all brake housing would be made of linear strands covered with something tough. this is what Yokozuna does, Jagwire offers some covers theirs with a braided Kevlar or other stuff. But all these suffer from extra friction, the liner is too close to the cable diameter. and they're a bit bigger than the standard 5mm, making some fitments awkward at best.

If the steel part is a helical coil , doesn't the plastic outer prevent the steel from untwisting somewhat in the event of torsion of the cable such as, for example, when the handlebars are swung from one side to the other? Not sure that untwisting & twisting a steel spiral is good for the wear of it. But respect for trying something different, nevertheless...

Broke down and got a pair of Aican Ultralite (Bungarus = Superlite) cable kits. Both the brake and der housings have longintudinal alloy strands wrapped in a kevlar sheath. The first section I cut, front brake, weighed 9gms. The Gore it replaced was 20gms. Not exactly cheap at $70/bike. But less painful than Nokon/iLinks/Bungarus.

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